So I have tried this now...
acrylian:
"You first need to understand how Zenphoto works. "
Well yes and no. First, I think I get the idea of what on the fly means. If a display of an image of a certain size is requested and it doesn't exist it's produced then and there, no? As for *needing* to understand how it works, maybe for making comments about how to solve the problems, but not for requesting how the user interface should act. That's a (volunteer) programmer's problem

. The user's job is to request the behavior

The behavior isn't impossible since g3 does it all quite well and the fact that on the fly methods is "how it works" doesn't get in the way of also adding tracking and communication needed to precache. Maybe then it just needs to work other ways too.
"With 1.4.3 themes can actually register image sizes with the cacheMAnager. "
Nice. It looked more like a hand entered table of values, but that's great.
sbillard:
"Of coure, registering sizes does not cause caching to occur. Since Zenphoto knows nothing of an image until it discovers it."
Well, then zenphoto is maybe lacking that functionality. The images are in the albums directory to be discovered. I can see that maybe you want the flexibility for some theme to have a different size for every image (that would be a fun theme for the user to configure). In that case it's hard, and maybe for that case you give up and only let every theme ask for a few sizes that most images use and on the fly the rest. You don't need to give up though. You certainly could have mechanisms for the theme to inform a precacher about what images need what. The only exception I see if the theme actually allows a web page users to demand arbitrary sizes. Then on the fly is on the fly.
So for example in G3 as soon as you change themes a message shows up saying you have X images that need updating. It doesn't just do it though, you still need to go run an admin tool when it says that. When you upload new images, I'm pretty sure then it's automatic though.
Anyway, I tried the beta. The pre-selections are nice and I don't even care if they theme is providing them or a developer is just keeping them updated. What difference does it make to me? Anyway, sadly, I still crashed, after slowly working through a few images! I did look at the code and image magic docs, and yes I see there aren't many choices in how to use imagick. It just does its thing as you say. I do notice that g3 uses the command line "convert" while ZenPhoto uses the php interface. I have no idea why g3 uses convert and wouldn't imagine that there would be any difference since it seems to have all the same options and surely uses the same binaries in the end. So I don't know why G3 works fine and not that slow even on my system and ZenPhoto crashes it. It appears to be related still to parallelism. I see mutliple httpd processes using large amounts of memory and disk I/O. In the end I probably just have to say ZenPhoto looks nice, but it seems my marginal resources just can't quite eek out a win on it and I should be glad that g3 manages to work somehow. I don't count that against ZenPhoto necessarily, just against it in my case. There's a chance I could restrict the number of servers while I precache and then open it up to come back online. I might play with it if I get time.
Thanks for the helpful replies.